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WO2025168473A1 - Procédé de surveillance d'un système de production et système de production correspondant - Google Patents

Procédé de surveillance d'un système de production et système de production correspondant

Info

Publication number
WO2025168473A1
WO2025168473A1 PCT/EP2025/052642 EP2025052642W WO2025168473A1 WO 2025168473 A1 WO2025168473 A1 WO 2025168473A1 EP 2025052642 W EP2025052642 W EP 2025052642W WO 2025168473 A1 WO2025168473 A1 WO 2025168473A1
Authority
WO
WIPO (PCT)
Prior art keywords
operating
paint
reference values
production plant
operating parameters
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2025/052642
Other languages
German (de)
English (en)
Inventor
Tobias Winter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Duerr Systems AG
Original Assignee
Duerr Systems AG
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Duerr Systems AG filed Critical Duerr Systems AG
Publication of WO2025168473A1 publication Critical patent/WO2025168473A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/4184—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by fault tolerance, reliability of production system
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31455—Monitor process status
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/31—From computer integrated manufacturing till monitoring
    • G05B2219/31483—Verify monitored data if valid or not by comparing with reference value
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B2219/00—Program-control systems
    • G05B2219/30—Nc systems
    • G05B2219/45—Nc applications
    • G05B2219/45065—Sealing, painting robot

Definitions

  • the invention relates to a monitoring method for a production plant (e.g., a paint shop). Furthermore, the invention relates to a corresponding production plant with a monitoring device that implements the monitoring method according to the invention.
  • a production plant e.g., a paint shop
  • a monitoring device that implements the monitoring method according to the invention.
  • Modern paint systems for painting automotive body components can operate in various operating states, which are differentiated by various operating variables and are also referred to as categories. For example, one operating state can be defined by the supply of blue paint at a paint pressure of 4.5 bar, while another operating state can be defined by the supply of red paint at a paint pressure of 4.5 bar.
  • the paint color (red or blue) and the paint pressure (4.5 bar) are therefore the variable operating variables that define the respective operating state.
  • the paint quantity can be measured as an operating parameter, which in the aforementioned first operating state with blue paint and a paint pressure of 4.5 bar can be in a range of 110 ml - 120 ml, while the paint quantity in the aforementioned second operating state with red paint and a paint pressure of 4.5 bar can be in a range of 130 ml - 135 ml.
  • the aforementioned limit values (minimum and maximum values) for the paint quantity form reference values for comparison with the respectively measured paint quantity as an operating parameter. If the specified range is exceeded, an error message can then be generated.
  • the problem with this known monitoring method is that a multitude of operating variables can be adjusted and measured during the operation of a paint shop. It is therefore difficult to specify appropriate reference values for the individual operating parameters for the various operating states.
  • the neural networks often used in machine learning are not easily readable by humans. Therefore, an operator cannot assess whether a particular operating state is already well represented by the underlying model.
  • the invention is therefore based on the object of providing a correspondingly improved monitoring method for a production plant. Furthermore, the invention is based on the object of providing a production plant that can implement the monitoring method according to the invention.
  • the monitoring method according to the invention is generally suitable for a production plant. However, the monitoring method according to the invention is preferably used for a coating plant for coating components (e.g., motor vehicle body components) with a coating agent (e.g., paint).
  • a coating plant for coating components (e.g., motor vehicle body components) with a coating agent (e.g., paint).
  • the operating parameter to be monitored in a painting system can be, for example, the paint quantity.
  • other operating parameters of the production system can also be measured and monitored. Examples of these operating parameters include the following.
  • the memory table stores the appropriate reference values for the operating parameter to be monitored (e.g., paint quantity) for various operating states (e.g., paint color and paint pressure).
  • the assignment of the operating states to the appropriate operating parameters is defined by so-called rules. In the simplest case, for each operating parameter to be monitored, there is a target value as a reference value and a permissible tolerance. If exceeded, the situation is classified as faulty. However, the rules can also be more complex. There are various options within the scope of the invention for determining the above-mentioned rules, which are briefly explained below.
  • Unsupervised learning This involves taking a rolling average from historical data and using it as a reference value. However, it can also involve a more complex calculation.
  • OK operating states i.e., operating states that are error-free and in order (e.g., time periods or individual workpieces). Only these are then used to calculate the reference value.
  • operating state used within the scope of the invention can also define a respective section ("brush") of a painting path traversed by a paint impact point of a painting robot.
  • Various operating variables e.g., paint flow, shaping air flow, rotational speed of a rotary atomizer, charging voltage of an electrostatic paint charge, etc.
  • paint flow e.g., paint flow, shaping air flow, rotational speed of a rotary atomizer, charging voltage of an electrostatic paint charge, etc.
  • the operating variables of the painting system can thus be dynamically changed from section to section as a painting path is traversed. Reference values can then be specifically specified for each section of the painting path and the associated operating state.
  • the invention also claims protection for a production facility designed to carry out the monitoring method according to the invention.
  • the production facility may be a coating facility for coating components (e.g., motor vehicle body components) with a coating agent (e.g., paint).
  • a coating agent e.g., paint
  • the invention is not limited to a coating facility with regard to the type of production facility.
  • the production system initially comprises several sensors to measure operating variables (e.g., paint color and paint pressure) and/or operating parameters (e.g., paint quantity) of the production system during operation.
  • operating variables e.g., paint color and paint pressure
  • operating parameters e.g., paint quantity
  • the applied paint quantity can be measured as an operating parameter in a painting system.
  • the production plant according to the invention in accordance with conventional production plants, has a control system for setting the desired operating state of the production plant and for querying the measured operating parameters (e.g., paint quantity) and/or operating variables (e.g., paint color and paint pressure) from the sensors.
  • the production plant according to the invention in accordance with known production plants, also comprises a monitoring device for monitoring the production plant by comparing the operating parameters of the production plant measured by the sensors with predetermined reference values for the operating parameters. Depending on the comparison, an error message or other reaction can then be triggered.
  • the production plant according to the invention is distinguished from the prior art in that the monitoring device has a memory table (database) for storing the reference values for the operating parameters in an assignment to the associated operating states.
  • database memory table
  • the monitoring device preferably has a control generator for determining the reference values for the operating parameters based on the measured operating parameters.
  • the control generator can determine the reference values for the respective operating state, for example, through unsupervised or unsupervised machine learning from historical measurement data of the operating parameters.
  • control generator can calculate the reference values as mean values of the measured operating parameters or use the operating parameters during a fault-free operating period or during a fault-free event as reference values.
  • the monitoring device can have a rule editor for manual input of the reference values by an operator.
  • Figure 1 shows a flow chart to illustrate the monitoring method according to the invention in a painting system for painting motor vehicle body components.
  • Figure 2 shows a flow chart to illustrate the determination of the reference values by forming a moving average of the measured operating parameters.
  • Figure 3 shows a modification of Figure 1, where the reference values are derived from the measured operating parameters during a fault-free operating period or during a fault-free event.
  • Figure 4 shows a schematic representation of a painting system according to the invention.
  • Figure 5 shows a schematic representation of a memory table according to the invention for the assignment of the reference values to the various operating states of the painting system.
  • Figure 6 shows a schematic representation of a painting track which is divided into track sections, with an operating state being specified and an operating parameter being monitored for each track section.
  • a desired operating state of the painting system is selected.
  • the operating state of the painting system is determined by the fact that red paint is to be applied at a paint pressure of 4.5 bar.
  • the operating state of the painting system can be determined by a variety of different operating variables.
  • reference values for the operating parameters of the paint shop are then read from a memory table, corresponding to the operating state previously selected in step S1.
  • the read reference value relates to the applied paint quantity, which is read from the memory table depending on the previously selected operating state.
  • the reference value can represent a maximum and a minimum value for the applied paint quantity.
  • the painting system is then operated according to the previously selected operating state, i.e. in this example with red paint with a paint pressure of 4.5 bar.
  • step S4 operating parameters of the paint shop are then measured in step S4.
  • the applied paint quantity is measured as the operating parameter.
  • the paint shop is monitored by comparing the measured operating parameter (paint quantity) with the reference values for this operating parameter. For example, when applying blue paint at a paint pressure of 4.5 bar, the applied paint quantity should be at a reference value of 120 ml, with a tolerance of 5 ml possible, as shown in Fig. 5.
  • an error signal can be output in step S6. Furthermore, the control system can then initiate appropriate countermeasures.
  • a desired operating state of the painting system is first selected, for example for painting red paint with a paint pressure of 4.5 bar.
  • the reference values for the operating parameters are then determined depending on the previously determined moving average of the measured operating parameter (e.g. applied paint quantity).
  • a special feature here is that a fault-free operating period or a fault-free event (e.g., a fault-free painted vehicle body) is determined during the paint shop's operation in the desired operating state.
  • the reference values for monitoring are then determined based on the operating parameters measured during the fault-free operating period or during the fault-free event.
  • Figure 4 shows a schematic representation of a production plant 1 according to the invention, which can be, for example, a painting plant for painting motor vehicle body components, as already mentioned above.
  • Production system 1 is initially connected to a controller 2 via an interface.
  • controller 2 can control production system 1 via the interface and set the desired operating state by specifying operating variables (e.g., paint color and paint pressure).
  • controller 2 can also query operating parameters (e.g., paint quantity) of production system 1 via the interface, which are measured by sensors in production system 1.
  • the control system 2 can then initially store the measured operating parameters (e.g. paint quantity) in a database 3 as raw data together with the specified operating variables (e.g. paint color and paint pressure).
  • the raw data stored in database 3 can then be processed and stored in processed form in another database 4.
  • a memory table 5 is provided in which reference values (e.g. maximum value and minimum value) are stored for the operating parameters (e.g. paint quantity) for different operating states (e.g. different paint colors and paint pressures) of the production plant 1.
  • reference values e.g. maximum value and minimum value
  • the operating parameters e.g. paint quantity
  • different operating states e.g. different paint colors and paint pressures
  • the reference values can be generated by an automatic rule generator 6, which contains the processed raw data from the database 4 and then stores the reference values in the memory table 5 in an assignment to the respective operating state.
  • the reference values can also be generated by a manual rule editor 7 and stored in the memory table 5, whereby the manual rule editor 7 can communicate with an operator 9 via a human-machine interface 8.
  • a monitoring module 10 which applies the previously generated rules and can influence the controller 2.
  • Figure 6 shows a schematic representation of a painting path 11, which is traversed by a paint impact point of an application device (e.g. rotary atomizer) which is guided by a multi-axis painting robot over the surface of the component to be painted.
  • the painting path 11 is defined by several path points P1-P8, which are arranged according to the Geometry of the component to be coated can be determined, which is also referred to as teaching.
  • the painting path 11 consists of several consecutive path sections BA1-BA7, whereby the operating state of the painting system can be dynamically adjusted in the individual path sections BA1-BA7 when traveling along the painting path 11. In each of the path sections BA1-BA7, various operating variables (e.g.
  • path speed, paint current, charging voltage of an electrostatic paint charge, etc. can be dynamically adjusted.
  • An operating state is therefore set for each of the path sections BA1-BA7.
  • a reference value for the operating parameter to be monitored can then be read out from the memory table for each of the path sections BA1-BA7 and the associated operating state.

Landscapes

  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Automation & Control Theory (AREA)
  • Spray Control Apparatus (AREA)

Abstract

L'invention concerne un procédé de surveillance destiné à un système de production (1), en particulier un système de revêtement permettant de revêtir des composants (par exemple des parties de carrosserie de véhicule à moteur) avec un agent de revêtement (par exemple, de la peinture), comprenant les étapes suivantes consistant à : définir un état de fonctionnement souhaité du système de production (1), en particulier en définissant une peinture souhaitée et une pression de peinture souhaitée pour peindre les parties de carrosserie de véhicule à moteur ; faire fonctionner le système de production (1) selon l'état de fonctionnement défini ; mesurer des paramètres de fonctionnement du système de production (1) pendant le fonctionnement du système de production (1) dans l'état de fonctionnement défini, en particulier par mesure d'une quantité appliquée de peinture ; et surveiller le système de production (1) en comparant les paramètres de fonctionnement déterminés à des valeurs de référence pour les paramètres de fonctionnement, les valeurs de référence étant définies par les étapes suivantes : définir les valeurs de référence pour les paramètres de fonctionnement sur la base des états de fonctionnement respectifs du système de production (1) pour une pluralité d'états de fonctionnement différents du système de production (1) ; stocker les valeurs de référence définies dans une attribution aux états de fonctionnement associés dans une table de mémoire (5) ; et lire les valeurs de référence à partir de la table de mémoire (5) sur la base de l'état de fonctionnement actuellement défini du système de production (1). En outre, l'invention concerne un système de production (1) permettant la mise en œuvre du procédé de surveillance.
PCT/EP2025/052642 2024-02-08 2025-02-03 Procédé de surveillance d'un système de production et système de production correspondant Pending WO2025168473A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102024103514.5 2024-02-08
DE102024103514.5A DE102024103514A1 (de) 2024-02-08 2024-02-08 Überwachungsverfahren für eine Produktionsanlage und entsprechende Produktionsanlage

Publications (1)

Publication Number Publication Date
WO2025168473A1 true WO2025168473A1 (fr) 2025-08-14

Family

ID=94480966

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2025/052642 Pending WO2025168473A1 (fr) 2024-02-08 2025-02-03 Procédé de surveillance d'un système de production et système de production correspondant

Country Status (2)

Country Link
DE (1) DE102024103514A1 (fr)
WO (1) WO2025168473A1 (fr)

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1984002592A1 (fr) 1982-12-23 1984-07-05 Digitale Steuerungssyst Dst Procede et installation pour la surveillance de processus
WO2006037137A1 (fr) 2004-10-05 2006-04-13 Keba Ag Surveillance d'une zone de travail pour machines et robots commandes par programme et automatises
US20090177439A1 (en) * 2006-04-14 2009-07-09 Samples Paul K Process Monitoring Technique and Related Actions
DE102009013561A1 (de) 2009-03-17 2010-10-07 Dürr Systems GmbH Überwachungsverfahren und Überwachungseinrichtung für eine elektrostatische Beschichtungsanlage
EP2320289A2 (fr) * 2009-10-30 2011-05-11 ABB Technology AG Procédé et dispositif de surveillance d'un processus et/ou d'une installation technique
US20140244567A1 (en) * 2007-08-23 2014-08-28 General Electric Company Systems and methods for prediction of trips
DE102015112361A1 (de) 2014-08-04 2016-02-04 GM Global Technology Operations LLC (n. d. Gesetzen des Staates Delaware) Rotations-Farbzerstäubersystem und Verfahren zum Überwachen eines Rotations-Farbzerstäubers
DE102019112099B3 (de) 2019-05-09 2020-06-18 Dürr Systems Ag Überwachungsverfahren für eine Applikationsanlage und entsprechende Applikationsanlage

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1984002592A1 (fr) 1982-12-23 1984-07-05 Digitale Steuerungssyst Dst Procede et installation pour la surveillance de processus
WO2006037137A1 (fr) 2004-10-05 2006-04-13 Keba Ag Surveillance d'une zone de travail pour machines et robots commandes par programme et automatises
US20090177439A1 (en) * 2006-04-14 2009-07-09 Samples Paul K Process Monitoring Technique and Related Actions
US20140244567A1 (en) * 2007-08-23 2014-08-28 General Electric Company Systems and methods for prediction of trips
DE102009013561A1 (de) 2009-03-17 2010-10-07 Dürr Systems GmbH Überwachungsverfahren und Überwachungseinrichtung für eine elektrostatische Beschichtungsanlage
EP2320289A2 (fr) * 2009-10-30 2011-05-11 ABB Technology AG Procédé et dispositif de surveillance d'un processus et/ou d'une installation technique
DE102015112361A1 (de) 2014-08-04 2016-02-04 GM Global Technology Operations LLC (n. d. Gesetzen des Staates Delaware) Rotations-Farbzerstäubersystem und Verfahren zum Überwachen eines Rotations-Farbzerstäubers
DE102019112099B3 (de) 2019-05-09 2020-06-18 Dürr Systems Ag Überwachungsverfahren für eine Applikationsanlage und entsprechende Applikationsanlage

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